Modular structures

ABSTRACT

A modular kit of parts creates structures to store and suspend equipment used for physical fitness. A structure can be created that can store fitness equipment such as exercise balls, dumb bells, kettle bells and the like. Further, the structure can incorporate exercise bars, and can store and deploy such equipment as suspension straps, punching bags, heavy bags, yoga straps, which are suspended from multi axial pivoting anchors that afford no frictional resistance when the equipment is utilized for exercise.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to modular structures and, more particularly, modules capable of being assembled into various articles of fitness facility equipment with the capability of storing and/or suspending various exercise accessories.

2. General Background and State of the Art

In most fitness facilities, structures to store and/or suspend equipment and accessories are individually created. Exercise apparatus generally requires a separate structure to accommodate it. Other structures such as vertically aligned parallel bars are installed as a wall fixture.

There are sources of modular equipment that can provide structures that can fit in spaces using standardized elements that are adjustable so that skilled installers are not required. One such system is shown and described in the application to Scaramucci, Publication No. US 2014/0054247. Other systems are designed for installation to a wall or ceiling. However, such structures are not necessarily designed to store equipment as a primary function and to accommodate exercise and physical training equipment that can be deployed for use and retrieved when free floor space is desired.

INVENTION SUMMARY

According to the present invention, a plurality of modular elements have been designed for the unique task of serving a physical fitness facility. These elements can create structures that can be configured into assemblies that store physical training equipment such as exercise balls, dumb bells, kettle bells and the like. Using unique, cantilevered shelves, these items, which collectively can be quite heavy, require special support afforded by the structures of the present invention.

Because of the weight of the objects that are being stored, the structures should be firmly embedded in the facility floor and some of the modules of the present invention make such attachments both simple and practicable. Using the inventory of modules, additional structures can be fabricated which can be elements of exercise and fitness devices such as suspension straps, climbing bars, punching bags, pull up bars, monkey bars, dip bars, seats, steps and other appliances for facilitating physical fitness exercises. Of course, wherever possible, existing “off the shelf” products will be integrated into the system.

The basic structural elements are powder coated box tubes of standard length. These can be both vertical and horizontal support members to which u-shaped channel members can be attached. To minimize inventory needs, basic tubes of a standard length are provided. Smaller tube increments can be attached to the standard tube to extend it to a desired greater length

The u-shaped channel members include a series of slots which accommodate tabs on shelf elements. While tabs and slots are well known combinations for adjustable shelving, the shelves of the present invention include oversized tabs which must be rotated for insertion into the slots. The shelves further include shelf support rods which bear against the channel to resist rotation of a shelf about the tabs when heavy objects are stored on the shelf. In alternative embodiments shelves are provided with pairs of tabs which can utilize more than one slot thereby providing multiple anchor points for the support of heavy equipment.

Special gussets are provided to cooperate with base plates for resisting tipping forces and other gussets are provided to permit cantilevered box tubes that can extend either to create additional structures or to support athletic equipment suspended therefrom. Parts are assembled utilizing conventional nuts and bolts. Where apertures in the box tubes are used for the connection of other elements that might place substantial stresses on the apertures, a special tube is mounted in the aperture to provide extra wall strength to the coupling device.

An integral part of the structure designed for the purpose of suspension is a multi-axial pivoting anchor useful in attaching a variety of exercise equipment such as, suspension training straps, punching bags, heavy bags, yoga hammocks, ropes, and the like to the modular structure of the present invention. The anchor is created during the product assembly process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled apparatus according to the present invention;

FIG. 2, INCLUDES FIGS. 2A, 2B AND 2C WHERE FIG. 2A IS A PERSPECTIVE VIEW OF THE BASE OF AN UPRIGHT WHERE IT FASTENS TO A SUBSTRATE WHILE FIG. 2B IS AN EXPLODED VIEW OF THE STRUCTURE OF FIG. 2A AND FIG. 2C IS AN ENLARGED VIEW OF A PORTION OF THE STRUCTURE;

FIG. 3 includes FIGS. 3A and 3B where FIG. 3A if a perspective view of the top of an upright with an orthogonal member attached thereto while FIG. 3B is an exploded view of FIG. 3A;

FIG. 4 is a perspective view of a slotted channel with a shelf installed therein;

FIG. 5 is a perspective view of the rear of the structure of FIG. 4;

FIG. 6 includes FIGS. 6A and 6B where FIG. 6A is perspective view of the front of a structure supporting shelves while FIG. 6B is a rear view of the structure of FIG. 6A;

FIG. 7 is detailed perspective view of the section of FIG. 1 identified by the reference numeral 7;

FIG. 8 is a side view of the structure of FIG. 1;

FIG. 9 is a plan view of a reinforced beam;

FIG. 10 is a side sectional view of the reinforced beam of FIG. 9, taken along line 10-10 in the direction of the appended arrows:

FIG. 11 is a plan view of an extender module;

FIG. 12 is a perspective exploded view of the module of FIG. 11 aligned with a post beam;

FIG. 13 including FIGS. 13a and 13b is a partial view of the structure, showing multi-axial pivoting anchors attached thereto and an exploded view showing the attachment;

FIG. 14, including FIG. 14a which shows the assembled anchor and FIG. 14b which shows the disassembled anchor;

FIG. 15, including FIGS. 15a and 15b show front and rear views of an alternative shelf mounting structure;

FIG. 16, including FIGS. 16a and 16b show perspective front and rear views of shelves with the alternative shelf mounting structure of FIG. 15; and

FIG. 17 is a partial view of an alternative embodiment of the bridge element using flanges to connect components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning first to FIG. 1, there is shown a structure 10 created from the modules of the present invention. As shown, the structure 10 includes a storage rack 12, wall bars 14, a storage bay 16, a bridge element 18 with integral monkey bars 20. Suspended from the wall bars 14 are a dip bar 22 and a step element 24.

The storage rack 12 includes a plurality of shelf elements 26 which can be configured to support balls 28 of various sizes, tubes 30, and other pieces of gym apparatus such as dumb bells, kettle bells and other weighty objects, none of which are shown as being stored in storage rack 12.

Mounted at the top of the storage rack 12 is a cantilever arm 32 with a mounting ring 34 at its outer end from which can be suspended other fitness elements such as training or fitness bags (not shown) or suspension straps 36 shown stored in the storage bay 16. A second cantilever arm 32′ extending from the storage bay 16 supports a pull up bar 38 as does the bridge element 18. A circle 7 encloses elements which are described in greater detail in FIG. 7.

The basic structural element is the post beam 40 which, in the preferred embodiment is a 6″×2″ tube with a standard length of 7 feet. Shorter tubes (not shown) can be coupled to achieve greater lengths using connector plates 42 which are shown to connect two beams 40 to form the bridge element 18. Gusset plates 44 connect vertical beams 40 to horizontal beams 40 to create either the cantilever arms 32 or the bridge elements 18. While, in the preferred embodiments, a u-shaped channel, shown and described in FIGS. 4 and 5, is provided to support shelves, in alternative embodiments, the beams 40 can be provided with slots on one or more sides to permit the installation of shelves, support pegs or support arms for the storage of other equipment, such as bar bells.

Turning next to FIG. 2 there is shown the structure that allows the assembled structures to be anchored to a floor or other substrate. While FIG. 2A shows the finished product, the constituent elements are best seen in FIG. 2B. A base plate 46 has fastening posts 48 to secure it to a beam 40. The base plate 46 has apertures 50 through which fastening bolts 52 or floor mounted bolts (not shown) can be inserted. Where bolts 52 are utilized, female threaded anchors 54 are secured into the floor. When the bolts 52 are used to secure the base plate 46 to the floor, it is preferable to use lock washers 56 and flat washers 58. In alternative embodiments, bolts can be embedded in the floor and the base plate 46 would be secured by nuts and washers.

In the preferred embodiment, a base gusset comprised of opposing flanged plates 60 is fastened to the beam 40. At a leading end of the flanges of the flanged plates 60, best seen in FIG. 2C, an aperture is provided for an additional bolt 52 for added restraint of the beam 40. For cosmetic purposes, a foot cover 62 is fastened over the front of the flanged plates 60. In alternative embodiments, the gusset plates used at the base of the beam 40 serving as a vertical support, could also be used to fasten horizontally oriented beams 40 to be cantilevered.

Such a connection is illustrated in FIG. 3. However, in the preferred embodiment, a different, upper gusset is also comprised of a pair of opposed, flanged upper gusset plates 64. In alternative embodiments, the same gusset plates could be used at both the top and bottom of the beams 40. As shown, a horizontally oriented beam 40 is positioned atop a vertically oriented beam 40. The flanges 66 hold the horizontal beam 40 in place, reducing the stress on the fasteners 68 which connect the gusset plates 64 to both beams 40.

Turning next to FIGS. 4 and 5 where there is shown in front and rear perspective views, a bracket channel 70 according to a preferred embodiment. The bracket channel 70 is adapted to be fastened to a wall of beam 40 to adjustably support shelves, pegs, brackets and other accessories that could be suspended from a beam 40. The bracket channel 70 is a u-shaped member with aligned elongated slots 72 in the side walls of the channel 70.

In the preferred embodiment, shelves are comprised of a bar 74 to which can be attached various brackets 76 that are shaped to accommodate the different accoutrements of fitness training. For example, various support elements are sized to fit different sized exercise balls. Other support elements can hold dumb bells. A plurality of support elements are maintained in inventory to be attached, as needed to a shelf bar 74.

At each end of a shelf bar 74 is an end plate 78 which has extending therefrom an elongated tab 80 which is longer than the slots 72. By tilting the end plate 78, the tab 80 can be inserted into a slot 72. Straightening the end plate 78 results in the tab 80 resting in the slot 72. In alternative embodiments, a notch may be provided on the lower surface of the tab 80 which can engage the lower edge of the slot 72 to lock the end plate 78 in place.

For additional support, the end plate 78 includes a support arm 82 which has, at its lower end, a support rod 84 that bears against the beam 40. This arrangement more strongly resists any rotational forces resulting from weighty objects being stored on the shelf. Absent the support arm 82 and rod 84, stress would be exerted only on the upper part of the tab 80. With the support arm 82 and rod 84, rotational forces would be converted into a force that is substantially lateral which can be resisted by both ends of the tab 80.

Turning next to FIGS. 6A and 6B, there is shown a typical storage rack 12. FIG. 6A is a front perspective view and FIG. 6B is a rear perspective view. The component parts have been described in earlier Figs. Shown here are alternative brackets for the support of fitness equipment. Common to the illustrated support brackets is the u-shaped cantilevered element which has a linear support brace 86 extending from the outermost end of the bracket to the shelf bar 74.

FIG. 7 is a more detailed view of the elements of the bridge structure shown in FIG. 1. A bridge connector plate 88 couples two beams 40 together.

FIG. 8 is a side view of the structure of FIG. 1 and need not be further described here.

FIG. 9 is a view of a post beam 40 which has been reinforced with tubular cylinders 90. These tubular cylinders 90 or crush tubes, bear the forces that result when post beams 40 are connected end-to-end with connecting plates 42 as in the bridge structures of FIG. 1. Absent the crush tubes 90, substantial stresses on the joint might bear on the apertures through which connectors would pass and cause deformations in the beam 40 wall.

All forces experienced by the connectors are distributed through the crush tubes 90. Because these tubes 90 are welded into place they protect the post beam 40 not only from orthogonal forces that would lead to bending, but also from any deformation of the side wall when the connectors are tightened.

FIG. 10 is a side view of the beam 40 of FIG. 9, and shows the crush tubes in place. As noted above, the tubes 90 are secured in place by welding or other permanent attachment to the beam 40. Should the connection plates 42 (not shown here) be subjected to forces that might deform the beam 40 walls, the tubes 90 can resist such forces and prevent any deformation.

Turning next to FIG. 11, there is shown an extender module 92 which can add a desired length to a beam 40 for those applications where a longer beam is required. The module 92 is so configured that a plurality can be connected end to end to extend the length by an amount that is less than the length of the beam 40. The extended module 92 has a first section 94 which has the same circumferential size and shape as a beam 40. A corrugated portion 96 is anchored in the first portion 94 and is sized to be inserted into a beam 40. As shown, four holes 98 are placed so that when the corrugated portion 96 is fully inserted into a beam 40 end, the holes in the beam 40 are aligned with the holes 98.

The exploded view of FIG. 12 shows the relationship of the component parts. With the corrugated portion 96 fully seated into the beam 40, connector elements, here bolts 100, washers 102 and nuts 104, fasten the extender module 92 to a beam 40.

Pivoting mechanisms 110 are attached to the structure at the ends of the beams 40 and along the bridge element 18 at specific locations as shown in FIG. 13a The pivoting anchors 110 are attached to a post beam 40 by inserting the ends of trunion axle 112 with bearings 116 through holes in adjoining mounting plates 118 which are bolted to the modular structure as shown in FIG. 13b . using bolts 120 which are secured with washers 122 and nuts 124 best seen in FIG. 13 b.

In FIGS. 14A and 14B, there is shown assembled and in exploded view, the multi-axial pivoting anchor 110 which is used to attach a variety of exercise equipment such as, suspension training straps, punching bags, heavy bags, yoga hammocks, ropes, and the like to the modular structure of the present invention and is an integral part of the modular structure. The anchor 110 is created during the product assembly process.

As shown in FIGS. 14A, 14B, the pivoting anchor mechanisms 110 is comprised of a central hub or trunion axle 112, secondary axle 114, shackle 126, trunion bearings 116, 116′ center bearing 118, thrust bearings 128, and capture bolt 132. The center bearing 118 is inserted into the trunion axle 112. Thrust bearings 128 are located between the shackle 126 and trunion axle 112. The secondary axle 114 is inserted through holes in the end of the shackle 126, continuing through the thrust bearings 128, through the center bearing 130 and contained with the capture bolt 132. The shackle 126 rotates freely around the secondary axle 114, while the trunion axle 112 rotates freely upon bearings 116, 116′.

The pivoting mechanism 110 allows for freedom of movement of any fitness equipment attached to the mechanism because the attached load pivots through two simultaneous axes. This apparatus is a replacement for chains, webbing straps, cables or other means which are attached to a fixed anchor point which creates a resistance to the natural rotating and pivoting nature of an object swinging and or turning through its range of motion. While the pivoting mechanism 110 is shown as attached to a beam, its use is not so limited. The mounting plates 118 can be affixed to any suitable structure such as a wall or ceiling mount, widening the applicability of this element of the present invention.

Turning next to FIGS. 15 and 16 where there is shown in front and rear perspective views, an alternative embodiment of apparatus for connecting a shelf bar 76′ to the bracket channel 70. described above in connection with FIG. 4 In the alternative embodiment, shelf elements 26′ are comprised of formed sheet metal of various shapes or designs. As in the above figures, there is provided a bar 74′ to which can be attached-various brackets 76′ that are shaped to accommodate the different accoutrements of fitness training.

At each end of each shelf bar 74′ is an end plate 78′ which has extending therefrom a pair of elongated tabs 80′. The end plate 78′ is long enough to utilize more than one slot 72. The tabs 80′ can be inserted into two slots 72 which, in this embodiment, are adjacent. As a result, two tabs 80′ rest in two slots 72. The upper tab 80′ provides the resistance against rotations that the support arm 82 of the preferred embodiment provides.

It should be noted that the use of the u-shaped bracket channel 70 with slots 72 allow shelves or the like to be mounted on both sides of a beam 40 at the same level using either of the disclosed mounting configurations. A pair of back-to-back shelves could accommodate elongated items that might not easily fit on a single shelf, adding greater flexibility to the storage capabilities of the modular structure of the instant invention.

Turning to FIG. 17, there is shown an alternative manner of coupling two beams 40 together. In the embodiment illustrated in FIG. 1, the beams 40 are joined by a connector plate 42. Here, an alternative is provided using flange couplers 140 to join beams end-to-end. Each beam 40′ is fitted with a flange coupler 140 at its end and beams 40′ are connected by bolting adjacent flange couplers 140 together. In a preferred embodiment, the flange couplers 140 are welded to the beam 40′ ends. Some beams 40′ have a flange at one end but other beams 40″ (not shown) have flanges at both ends to create longer structures.

While the specification describes particular embodiments of the present invention, those of ordinary skill can devise variations of the present invention without departing from the inventive concept.

The scope of the invention should be limited only by the scope of the claims appended hereto. What is claimed as new is: 

1. (canceled)
 2. (canceled)
 3. (canceled)
 4. Apparatus for securing support devices comprising in combination: at least a pair of u-shaped channel members having a plurality of slots in the extending walls; an elongated support device having a first tab at each end of said device, said first tabs being sized and configured for insertion into said channel members slots; and stabilizing means adjacent said tabs for resisting rotational forces when objects are placed on said support device.
 5. Apparatus as in claim 4, wherein said stabilizing means include second tabs sized and configured for insertion into slots above the slots receiving said first tabs.
 6. Apparatus as in claim 4 wherein said stabilizing means include arms extending downward to engage the extending wall containing the slots into which said first tabs are to be inserted.
 7. A device for holding and storing objects comprising: a fixed vertical support frame having at least one longitudinal shelf element capable of at least partial longitudinal rotation about a first axis extending horizontally from a first side of said support frame, said first side having a first slot; a first hook for reversibly attaching first end of said shelf element to said first slot; at least one depending element attached to said shelf first end, said depending element having a first portion substantially perpendicular to said shelf element and a second portion at a remote end of said depending element positioned to contact said first side of said support frame to restrict said shelf element's rotation about said first axis.
 8. The device of claim 7 wherein a second depending element is connected to the opposite end of said shelf element.
 9. A device for holding and storing objects comprising: a fixed vertical support frame having at least one longitudinal shelf element capable of at least partial longitudinal rotation about a first axis extending horizontally within said support frame; a first slot in said vertical support frame; a second slot in said vertical support frame disposed above said first slot; a first hook attached to said shelf element for reversibly connecting said shelf element to said first slot; and a second hook attached to said shelf element above said first hook for reversibly connecting said shelf element to said second slot; whereby said second hook resists rotation of said shelf element.
 10. The device of claim 9 wherein said support frame has a pair of slots in a side opposite that containing said first and second slots; third and fourth hooks attached to the opposite end of said shelf element, said third and fourth hooks being adapted to reversibly connect to said third and fourth slots to resist rotation of said shelf element. 